Trim molding system and apparatus

ABSTRACT

A trim molding system including trim pieces having a tab and corresponding keyway system. The tab fits into the keyway. Trim boards having keyways are configured to be joined to a corner cap having tabs to provide a trim system that is suitable for use with bullnose corner bead. Trim boards having are configured to be spliced using a splice tab that both joins and aligns the trim boards. Trim boards having keyways are configured to be joined at a corner using an angled corner tab that both joins and aligns the trim boards, and conforms to a corner angle of a surface such as a wall.

The present application claims priority under 35 U.S.C. § 119(e), and any other applicable laws, to U.S. Provisional Application No. 60/741,467, entitled “Trim Molding System”, filed Dec. 2, 2005, which is incorporated herein by reference in its entirety.

FIELD

Embodiments of the present invention relate generally to construction materials and, more particularly, to trim molding.

BACKGROUND

The trim molding system and apparatus described by the embodiments shown herein has been conceived and created to address, among other things, a current limitation of trim pieces for walls having a “bullnose” or rounded corner. Embodiments can also be applicable to trim pieces installed at angled corners and for splicing trim pieces to be installed along a flat surface.

At the present time, builders installing interior rounded corner bead on drywall corners, can typically use mitering on a plurality of trim pieces, for example, two 22 and ½ degree miters, to wrap various trim molding around corners. Multiple mitering can represent a difficult and time consuming process. Further, the results of the finished trim work can not be aesthetically or visually desirable because of a choppy trim transition around an otherwise rounded corner.

The invention of the “corner cap” (as shown in PCT Application No. PCT/US2004/031961, also by the present inventor) can make transitioning trim molding around a bullnose corner easier and more visually appealing by reducing or eliminating mitering and can give the trim molding a smoother transition around the corner, providing an improved visual appearance that is more consistent with a rounded corner aesthetic. However, during development and application of embodiments of the corner cap invention, it has proven difficult to consistently match the profile of the injection molded plastic corner cap (which can be produced with very consistent dimensions) to the wood trim molding boards. Because construction suppliers can typically obtain trim molding from multiple manufacturers, some of which can use different tolerances and machines to produce the “same” molding profile, the trim boards can have variations in dimensions. These variations can be in thickness, height and/or location of profile lines and make it difficult to get a consistent match between the plastic corner cap and the wood trim board.

SUMMARY

Embodiments can address the above-referenced problem of aligning a molded plastic corner cap with a milled wood trim board, among other things. The inventor has discovered that a potential solution to this profile matching problem can include molding both the corner cap and the trim molding pieces from the same or similar material, for example,. ABS plastic or similar material, thereby producing trim pieces having similar dimensional tolerances. In addition to potentially solving the profile matching issue, embodiments can also allow for an improved connection between trim molding pieces and the corner cap, or between trim molding pieces, by providing a “tab” and “keyway” system that joins two components together.

At least one embodiment can include a trim molding system comprising a first trim piece, a second trim piece, and a corner cap. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening an a side of the second trim piece. The corner cap can include a top, bottom, front, back, a first side, and a second side. The corner cap can have a first tab extending from the first side and a second tab extending from the second side. The first tab can be configured to fit into the first keyway of the first trim piece and the second tab can be configured to fit into the second keyway of the second trim piece. Thus, the first and second trim pieces can be joined with the corner cap. Further, the first trim piece, the second trim piece, and the corner cap can each have a matching trim profile that is substantially continuous when the first trim piece and the second trim piece are joined to the corner cap. The phrase “substantially continuous,” as used herein, means an outward surface of at least one side of a trim piece is flush with the corresponding outward surface of a mating piece.

At least one further embodiment can include a trim molding system comprising a first trim piece, a second trim piece, and a splice tab. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening on a side of the second trim piece. The splice tab can be configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece are spliced together. Further, the first trim piece and the second trim piece can each have a matching trim profile that is substantially continuous when the first trim piece and the second trim piece are spliced using the tab.

At least another embodiment can include a trim molding system having a first trim piece, a second trim piece, and an angled corner tab. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening on a side of the second trim piece. The angled corner tab can be configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece meet at an angle corresponding to the angled corner tab.

For example, various embodiments can include trim molding pieces, corner caps, splice tabs, or angled corner tabs made of an extruded ABS, other plastic or similar material suitable for use as trim molding. An exemplary trim molding piece can include a female “keyway” molded into the interior of the trim molding piece and disposed toward the back surface of the trim molding piece. A tab can be inserted into the keyway in order to, for example, splice trim pieces, join trim pieces at a corner, or join trim pieces to a corner cap. The tab and keyway system can thus provide for a joint between trim pieces that is self-aligning and produces a trim profile that is aligned and/or produces a continuous trim profile around a bullnose corner bead.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a side elevation view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;

FIG. 2 provides an orthogonal view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;

FIG. 3 provides a perspective view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;

FIG. 4 provides a front elevation view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;

FIG. 5 provides an orthogonal view of exemplary trim pieces, including two trim boards and a corner cap, in accordance with the with at least one embodiment;

FIG. 6 provides an orthogonal view of an exemplary trim splice tab in accordance with at least one embodiment;

FIG. 7 provides an orthogonal view of an exemplary trim angled corner tab in accordance with at least one embodiment;

FIG. 8 provides an orthogonal view of an exemplary embodiment of the present invention in which two trim boards are to be spliced using a splice tab in accordance with at least one embodiment;

FIG. 9 provides an orthogonal view of an exemplary embodiment of the present invention in which two trim boards are to be joined at an inside corner using an angled corner tab in accordance with at least one embodiment; and

FIG. 10 provides an orthogonal view of at least one embodiment in which two trim boards are to be joined at an outside corner using an angled corner tab.

DETAILED DESCRIPTION

FIGS. 1 and 2 each show a portion of an exemplary trim molding piece in accordance with various embodiments. In particular, a trim molding piece 10 can comprise a front surface 12, a partially open back 14, a top 16, a bottom 18, and a keyway 20. The keyway 20 can comprise a top keyway slot 22 and a bottom keyway slot 24. The top keyway slot 22 and bottom keyway slot 24 can, for example, be about ⅛ inch wide and the keyway 20 can be dimensioned in height according to the trim molding piece. Further, the location of the keyway 20 relative to the back 14 of the trim molding piece 10 can vary. It should be appreciated that the dimensions and placement of the keyway 20 can vary according to a contemplated use and by taking into account various considerations, such as, for example, a particular trim type, shape and size, among other things, without departing from the spirit and scope of the present invention.

Still referring to FIGS. 1 and 2, the top 16 of the trim molding piece 10 can include a top portion 26 and a bottom portion 28, which both substantially contact a surface, such as a wall, when the trim molding is installed. The top portion 26 of the back 14 of the trim molding piece 10 can have a thickness 27. The bottom portion 28 of the back 14 of the trim molding piece 10 can have a thickness 29. The thicknesses 27 and 29 can be, for example, about ⅛ inch for typical trim molding applications. However, it should be appreciated that the thicknesses 27 and 29 can vary according to a contemplated use and by taking into account, for example, a particular trim type, shape and size, among other things, without departing from the spirit and scope of the present invention. The front 12 of the trim molding piece 10 can include a trim profile 30 that gives the trim an ornamental or decorative visual appearance. While the back 14 is shown partially open, it should be appreciated that the back 14 can be formed fully open or fully closed.

FIGS. 3 and 4 each show a portion of an exemplary corner cap in accordance with various embodiments. In particular, a corner cap 32 can comprise a front 34, a profile 30, a back 36, a top 38, a bottom 40 and a tab 42. The tab 42 can include a front tab surface 44, a back tab surface 46, a side tab surface 48, a top 50, and a bottom 52. Further the tab 42 has a height 54, a width 56, a thickness 58 and corners 60.

The tab 42 can function as a connecting means and can be formed so as to mate with the keyway 20 of a trim molding piece 10 when the corner cap 32 and the trim molding piece 10 are joined. The tab 42 can be formed as a part of the corner cap 32, or as a separate element design for inserting into the corner cap 32. In other words, the corner cap 32 can be formed with a keyway into which the tab 42 is inserted. The height 54 of the tab 42 is related to the height of the keyway 20 (FIGS. 1 and 2) such that the tab 42 and the keyway 20 can be joined, for example using a press fit. Other methods of joining the tab 42 and the keyway 20 can be used including adhesives, fasteners, detents, interlocking members, or the like. For example, the thickness 58 of the tab 42 can be dimensioned such that the tab 42 engages the top keyway slot 22 and the bottom keyway slot 24 in a press fit arrangement. The width 56 of the tab 42 is such that it is sufficient to provide a sturdy joint between a trim molding piece 10 and a corner cap 32. For example, the tab 42 can have a width of ½ inch to 1 inch for a typical trim molding piece application. It should be appreciated that the tab can be dimensioned according to a contemplated use of the invention by taking into account, among other things, a particular trim type, shape and size; a particular corner configuration, and/or the like.

FIG. 4 also shows a top of tab to top of corner cap dimension 62 and a bottom of corner cap to bottom of tab dimension 64, according to various embodiments. These dimensions can correspond to the positioning of the keyway 20 relative to the trim molding piece 10. The tab 42 can be positioned relative to the back 36 of the corner cap 32 to correspond to the placement of the keyway 20 relative to the back 14 of the trim molding piece 10. The placement and dimensions of the keyway and tab can depend on numerous factors including a particular trim type, shape and size, and can vary without departing from the spirit and scope of the present invention.

FIG. 5 shows an exploded view of two exemplary trim molding pieces and an exemplary corner cap in accordance with various embodiments. In particular, a corner cap 32 is shown prior to being joined to two trim molding pieces 10. When assembled, the tabs 42 on each side of the corner cap 32 can slide into the respective keyways 20 of the trim molding pieces 10.

This configuration of a trim molding system including trim molding pieces 10 and a corner cap 32 can provide for a smooth transition of the trim profile around a corner having a radius. In other words, the trim profile can be maintained substantially continuously around the corner.

FIG. 6 shows an exemplary splice tab in accordance with various embodiments. A splice tab 66 can comprise a front 68, a back 70, a top 72, a bottom 74, a first side 76 and a second side 78. The splice tab 66 can be configured to fit into keyways provided in the sides of two adjacent trim molding pieces in order to provide a splice, or butt joint. Thus, the splice tab 66 can be dimensioned, for example, to allow for a press fit into the keyways of trim molding pieces for which the splice tab has been constructed to splice together. When assembled, the splice tab 66 should preferably extend about halfway into a keyway of each adjacent trim molding piece. In other words about half of the splice tab 66 will be in one keyway and the other half of the splice tab 66 will be in the keyway of the adjacent trim molding piece. The splice tab can be provided with a notch, detent, or other feature to indicate a halfway point in order to aid in the splicing of trim pieces.

FIG. 7 shows an exemplary angled corner tab in accordance with various embodiments. An angled corner tab 80 can comprise a first tab side 82, a second tab side 84, an angled corner 86, a front 88, a back 90 a top 92 and a bottom 94. The angled corner tab can be configured to join two trim molding pieces in an angled corner arrangement. When assembled, the first side tab 82 can be inserted into one trim molding piece, and the second tab side 84 can be inserted into another trim molding piece such that the two trim molding pieces will meet at a joint angle θ determined by the angle of the angled corner 86 of the angled corner tab 80. Further, the two trim molding pieces can be mitered according to the angle of the angled corner tab 80. The angled corner tab can be provided at an inside or outside corner. It should be appreciated that the angled corner tab can be formed at various corner angles in accordance with a contemplated use.

FIG. 8 shows two exemplary trim molding pieces and an exemplary splice tab prior to splicing the trim molding pieces with the splice tab. In particular two trim molding pieces 10 are shown prior to being sliced with a slice tab 66. When assembled, the splice tab 66 will be inserted into the keyways 20 of the two trim molding pieces 10. The splice tab 66 and keyways 20 (one of which is shown) can operate to align the trim pieces such that when attached to a surface, such as a wall, the trim pieces are aligned at the splice joint.

FIG. 9 shows two exemplary trim molding pieces and an exemplary angled tab, in accordance with the present invention, prior to being joined on an inside corner. In particular, two trim molding pieces 10 are shown prior to being joined at a corner by an angled corner tab 80. When assembled, the angled corner tab 80 will be inserted into the keyways (not visible in this figure) of the two trim molding pieces 10. The angled corner tab 80 and keyways (not visible in this figure) can operate to align the trim pieces such that when attached to a surface such as a wall the trim pieces are aligned at the corner.

FIG. 10 shows two exemplary trim molding pieces and an exemplary angled tab, in accordance with various embodiments, prior to being joined on an outside corner. In particular, two trim molding pieces 10 are shown prior to being joined at an outside corner by an angled corner tab 80. The trim molding pieces 10 are shown with mitered edges 96. When assembled, the angled corner tab 80 will be inserted in to the keyways (not visible in this figure) of the two trim molding pieces 10. The angled corner tab 80 and keyways (not visible in this figure) can operate to align the trim pieces such that when attached to a surface such as a wall the trim pieces are aligned at the corner.

The trim molding pieces can be attached to the wall surface, or other surface, by using fasteners, adhesives, or any other means of attachment suitable for attaching trim to a surface. The trim molding pieces 10 can be cut to any desired length and still allow for the connection of the corner cap tab 42 (as shown in FIGS. 3 and 4), splice tab, or angled corner tab to the trim molding keyway 20 (as shown in FIGS. 1 and 2). The tab 42 can aid in aligning the molding profile of the components and can provide a tight joint at the connection (see, for example, FIG. 5).

The “keyway” and “tab” according to various embodiments can be used for any molding types or profiles, for example: baseboard, chair rail, crown molding and/or any other trim moldings. Further, the keyway and tab according to various embodiments can be used for elements other than molding, such as wire or cable covers, and/or other structural or functional elements where it can be desirable to use a keyway and tab system and corner caps.

Further, the “keyway” in the trim molding pieces can also allow for a connecting splice tab for splicing long runs of trim molding along a wall surface (see FIG. 8), as well as for both inside and outside angled corners (e.g. ninety degree corners) (see FIGS. 9 and 10). The tabs (splice, angled corner and corner cap) can also aid in aligning the molding profile and provide a tight joint at the connection. Although 90 degree corners are shown, it should be appreciated that the trim system can be used with other corner angles.

The tabs and keyways are preferably joined with a press fit, but can also be joined using an adhesive or a fastener. An adhesive can have an advantage of providing additional strength to the joint.

Embodiments of the trim molding pieces can be manufactured using a variety of materials and techniques, including, for example, extruded plastic. The extruded trim molding pieces can be attached to a wall or other surface using traditional fasteners such as nails or screws. The fasteners can be applied either manually (e.g. with a hammer) or automatically (e.g. pneumatic nail gun). Alternatively, the extruded trim molding pieces can be affixed to a wall or other surface using an adhesive. Depending on the material the trim pieces are made of, the trim pieces can be cut and sanded like traditional wood trim pieces.

A joint between trim pieces or between a trim piece and a corner cap is preferably very small, but in the case where the joint is noticeable, the joint can be filled with putty, caulk, and adhesive and/or other material suitable for filling such joints. Further, the joints between trim pieces or between trim pieces and a corner cap can be glued with an adhesive suitable for use with the material comprising the trim pieces and corner cap.

It is, therefore, apparent that there is provided in accordance with the present disclosure, a trim molding system. While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, applicants intend to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention. 

1. A trim molding system comprising: a first trim piece including a front, a back, a top, and a bottom, and having a first keyway formed in the first trim piece, the first keyway having an opening on a side of the first trim piece; a second trim piece including a front, a back, a top, and a bottom, and having a second keyway formed in the second trim piece, the second keyway having an opening on a side of the second trim piece; and a corner cap having a top, a bottom, a front, a back, a first side, and a second side, and having a first tab extending from the first side and a second tab extending from the second side; wherein the first tab is configured to fit into the first keyway of the first trim piece and the second tab is configured to fit into the second keyway of the second trim piece such that the first and second trim pieces are joined with the corner cap, and wherein the first trim piece, the second trim piece, and the corner cap each have a matching trim profile that is substantially continuous when the first trim piece and the second trim piece are joined to the corner cap.
 2. The trim molding system of claim 1, wherein the first tab and the second tab are formed integrally with the corner cap.
 3. The trim molding system of claim 1, wherein the first tab and the second tab are formed separately from the corner cap.
 4. The trim molding system of claim 3, wherein the corner cap further comprises a first corner cap keyway formed into the first side of the corner cap and a second corner cap keyway formed into the second side of the corner cap.
 5. The trim molding system of claim 4, wherein, when the first trim piece, the second trim piece, and the corner cap are joined, the first tab is inserted into the first corner cap keyway and the second tab is inserted into the second corner cap keyway.
 6. The trim molding system of claim 1, wherein the first trim piece, the second trim piece, and the corner cap are each formed of extruded plastic.
 7. A trim molding system comprising: a first trim piece including a front, a back, a top, and a bottom, and having a first keyway formed in the first trim piece, the first keyway having an opening on a side of the first trim piece; a second trim piece including a front, a back, a top, and a bottom, and having a second keyway formed in the second trim piece, the second keyway having an opening on a side of the second trim piece; and a splice tab configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece are spliced together; and wherein the first trim piece and the second trim piece each have a matching trim profile that is aligned so as to be substantially continuous when the first trim piece and the second trim piece are spliced using the splice tab.
 8. The trim molding system of claim 7, wherein the first trim piece, the second trim piece, and the splice tab are each formed of extruded plastic.
 9. A trim molding system comprising: a first trim piece including a front, a back, a top, and a bottom, and having a first keyway formed in the first trim piece, the first keyway having an opening on a side of the first trim piece; a second trim piece including a front, a back, a top, and a bottom, and having a second keyway formed in the second trim piece, the second keyway having an opening on a side of the second trim piece; and an angled corner tab configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece meet at a joint angle defined by the angled corner tab.
 10. The trim molding system of claim 9, wherein the first trim piece, the second trim piece, and the angled corner tab are each formed of extruded plastic.
 11. The trim molding system of claim 9, wherein the angled corner tab, when inserted into the first trim piece and the second trim piece, aligns the top of first trim piece with the top of the second trim piece.
 12. A bullnose corner molding cap, comprising: a corner cap having a curved portion configured to conform to a bullnose corner of a wall, and having first and second ends; wherein the ends each include a keyway configured to accept a connecting means, the connecting means being configured to attach the first end to a first trim piece and the second end to a second trim piece; and wherein the keyway and the connecting means cooperate to achieve a matching trim profile for the corner cap, first trim piece, and second trim piece when assembled together. 